HC4900 system service manual

CONTENTS
1 Warning ....................................................................................................................................5
2 System description ...................................................................................................................6
2.1 System function ...................................................................................................................... 6
2.2 Description Of A Can Bus System ............................................................................................ 6
2.3 System structure ...................................................................................................................... 8
2.4 HC4900 Central Unit............................................................................................................... 8
2.4.1 Performance parameter of central unit ............................................................................... 9
2.4.2 Port configuration of central unit ....................................................................................... 9
2.4.3 Port configuration for the application on XCMG telescopic crane ...................................... 10
2.4.4 Digital input port ........................................................................................................... 11
2.4.5 Digital output port.......................................................................................................... 11
2.4.6 PWM output Port ........................................................................................................... 11
2.4.7 Power and ground Port ................................................................................................... 12
2.4.8 Relay Port ..................................................................................................................... 12
2.5 CAN junction box ................................................................................................................. 12
2.6 IC4600 console ..................................................................................................................... 13
2.6.1 Performance parameter of IC4600 ................................................................................... 13
2.6.2 The information showing on the main interface ................................................................ 15
2.6.3 Function operation ......................................................................................................... 16
2.6.4 ANGLE LIMIT ............................................................................................................. 16
2.6.5 CAN-Bus state............................................................................................................... 18
2.6.6 OM code inquire ............................................................................................................ 19
2.6.7 OM code setting ............................................................................................................ 19
2.6.8 Reeving setting .............................................................................................................. 20
2.6.9 Fault Help ..................................................................................................................... 20
2.6.10 Horn off ........................................................................................................................ 21
2.6.11 A2B indicating light ....................................................................................................... 21
2.6.12 Pre-warning light ........................................................................................................... 21
2.6.13 Overload warning light ................................................................................................... 22
2.7 Pressure transducer................................................................................................................ 22
2.8 Length and angle sensor ........................................................................................................ 22
2.9 Length sensor ....................................................................................................................... 23
2.10 A2B switch ........................................................................................................................... 23
2.11 Wind speed ........................................................................................................................... 24
3 Trouble shooting .....................................................................................................................25
3.1 Length Sensing ..................................................................................................................... 25
3.2 Angle Sensing....................................................................................................................... 29
3.3 CAN conversion board .......................................................................................................... 32
3.4 Pressure transducer................................................................................................................ 32
3.5 Length sensor (LG105/11.5)................................................................................................... 33
3.6 A2B switch ........................................................................................................................... 33
3.7 Wind speed ........................................................................................................................... 36
3.8 No console display ................................................................................................................ 38
 3.9 No power in central unit ........................................................................................................ 38
3.10 CAN-BUS Communication .................................................................................................... 39
3.10.1 E61 ............................................................................................................................... 40
3.10.2 E62 ............................................................................................................................... 40
3.10.3 E63 ............................................................................................................................... 41
3.10.4 E64 ............................................................................................................................... 41
3.10.5 E94 ............................................................................................................................... 42
4 System Communication Cable ................................................................................................43
4.1 The communication cable of console ...................................................................................... 44
4.2 The Cable of pressure transducer ............................................................................................ 44
4.3 The cable of length/angle sensor............................................................................................. 45
4.4 Calibration Cable of LMI ....................................................................................................... 45
5 drawings .................................................................................................................................46
5.1 System topology diagram....................................................................................................... 46
5.2 Central unit to crane wiring diagram ....................................................................................... 47
5.2.1 Earlier version ............................................................................................................... 47
5.2.2 The latest version ........................................................................................................... 48
5.3 Central unit to CAN junction box wiring diagram .......................................... 错误!未定义书签。
5.4 CAN junction box to other sensors wiring diagram ........................................ 错误!未定义书签。
5.5 Cable reel wiring diagram ............................................................................ 错误!未定义书签。
6 Spare part listings ......................................................................................... 错误!未定义书签。
6.1 Central unit, HC4900 part no. 01490000100.................................................. 错误!未定义书签。
6.2 CAN junction box, part no. 04494600100 ..................................................... 错误!未定义书签。
6.3 IC4600 display, part no. 02460000200 .......................................................... 错误!未定义书签。
6.4 Length/Angle sensor, part no. 03520802000 .................................................. 错误!未定义书签。
6.5 Length sensor (LG105), part no.03510500300 ............................................... 错误!未定义书签。
6.6 system cables .............................................................................................. 错误!未定义书签。
7 Upload system software ............................................................................... 错误!未定义书签。
7.1 Software Setting.......................................................................................... 错误!未定义书签。
7.2 Upload system files ..................................................................................... 错误!未定义书签。
7.2.1 Upload system bottom files................................................................... 错误!未定义书签。
7.2.2 Uploading Control program files ........................................................... 错误!未定义书签。
7.2.3 Uploading LMI files............................................................................. 错误!未定义书签。
7.2.4 Uploading data files ............................................................................. 错误!未定义书签。
7.2.5 Time and Date Setting .......................................................................... 错误!未定义书签。
7.3 Data backup ................................................................................................ 错误!未定义书签。
7.4 Backup DAT data ........................................................................................ 错误!未定义书签。
7.5 Backup TLK data ........................................................................................ 错误!未定义书签。
8 PDB Variables .............................................................................................. 错误!未定义书签。
8.1 PDB variable and meanings in HC4900 system ............................................. 错误!未定义书签。
8.1.1 PDB variable sent by the console .......................................................... 错误!未定义书签。
8.1.2 PDB variable sent by the central unit ..................................................... 错误!未定义书签。
8.1.3 PDB variable sent by external sensor ..................................................... 错误!未定义书签。
8.2 PDB variable monitor .................................................................................. 错误!未定义书签。
9 LMI Calibration ............................................................................................. 错误!未定义书签。
 9.1 Basic adjustment for sensors ........................................................................ 错误!未定义书签。
9.1.1 Zero Point set of length sensor .............................................................. 错误!未定义书签。
9.1.2 Zero Point set of Angle sensor .............................................................. 错误!未定义书签。
9.1.3 Correct WG zero point online ............................................................... 错误!未定义书签。
9.1.4 Correct LG limitation online ................................................................. 错误!未定义书签。
9.1.5 Area ratio of rod and piston calibration .................................................. 错误!未定义书签。
9.2 General Debugging by iTool5 ...................................................................... 错误!未定义书签。
9.2.1 Function key introduction ..................................................................... 错误!未定义书签。
9.2.2 ITOOL adjusting procedure diagram ..................................................... 错误!未定义书签。
9.2.3 Adjust empty load ................................................................................ 错误!未定义书签。
9.2.4 Calibrating the radius of empty load ...................................................... 错误!未定义书签。
9.2.5 Load radius calibration ......................................................................... 错误!未定义书签。
9.2.6 Load percentage calibration .................................................................. 错误!未定义书签。
9.2.7 Modify the program status .................................................................... 错误!未定义书签。
9.2.8 Principles of linearity ........................................................................... 错误!未定义书签。
9.2.9 Notes of calibration .............................................................................. 错误!未定义书签。
10 Error code .............................................................................................. 错误!未定义书签。
11 Troubleshooting Moisture ....................................................................... 错误!未定义书签。
11.1 Water Ingress .............................................................................................. 错误!未定义书签。
11.2 Condensation .............................................................................................. 错误!未定义书签。
 The manufacturer reserves the right to modify the contents of this manual without notice.
Hirschmann will not be liable for errors contained in this manual or for incidental or consequential
damages in connection with the furnishing, performance, or use of this manual. This document
contains proprietary information, which is protected by copyright, and all rights are reserved.

No part of this document may be photocopied, reproduced, or translated to another language

without the prior written consent of Hirschmann.

Hirschmann reserves proprietary rights to all drawings, photos and the data contained therein.
The drawings, photos and data are confidential and cannot be used or reproduced without the
written consent of Hirschmann. The drawings and/or photos are subject to technical
modification without prior notice.

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

This service manual is designed to assist a service or maintenance person in

identifying system problem areas or malfunctions. A digital voltmeter with the
capability to measure current will be required, along with standard maintenance and
service tools.

NOTE: Knowledge of how to use a voltmeter to measure both voltage and current is
assumed.

1 WARNING

The LMI is an operational aid that warns a crane operator of approaching overload
conditions and over hoist conditions that could cause damage to equipment and
personnel.

The device is not, and shall not be, a substitute for good operator judgment,
experience and use of accepted safe crane operating procedures.

The responsibility for the safe crane operation shall remain with the crane operator
who shall ensure that all warnings and instructions supplied are fully understood and
observed.

Prior to operating the crane, the operator must carefully and thoroughly read and
understand the information in this manual to ensure that he knows the operation and
limitations of indicator and crane.

Proper functioning depends upon proper daily inspection and observance of the
operating instructions set forth in this manual. Refer to Section 6. Pre-Operation
Inspection and Calibration Verification of the operator’s manual.
The LMI can only work correctly, if all adjustments have been properly set. For correct
adjustment, the operator has to answer thoroughly and correctly all questions asked
during the setup procedure in accordance with the real rigging state of the crane. To
prevent material damage and serious or even fatal accidents, the correct adjustment
of the LMI has to be ensured before starting the crane operation.

2 SYSTEM DESCRIPTION

2.1 SYSTEM FUNCTION

The HC4900 system is a CAN bus system made up of a central microprocessor unit,
operating console, length/angle sensor, pressure transducers, and anti-two block
switches. All components and sensors are equipped with CAN bus controllers.

The Load Moment Indicator system operates on the principle of reference/real

comparison. The real value, resulting from the pressure measurement is compared
with the reference data, stored in the central processor memory and evaluated in the
microprocessor. When limits are reached, an overload warning signal is generated at
the operator’s console. At the same time, the aggravating crane movements, such as
hoist up, telescope out and boom down, will be stopped.

The fixed data regarding the crane, such as capacity charts, boom weights, centers of
gravity and dimensions are stored in memory chips in the central processor unit. This
data is the reference information used to calculate the operating conditions.

Boom length and boom angle are registered by the length/angle sensor, mounted
inside the cable reel, which is mounted on the boom. The boom length is measured by
the cable reel cable, which also serves as an electrical conductor for the anti
two-block switches.

The crane load is measured by pressure transducer block attached to the piston and
rod side of the hoist cylinders.

The interactive user guidance considerably simplifies the input of operating modes as
well as the setting of geometry limit values.

2.2 DESCRIPTION OF A CAN BUS SYSTEM

CAN stands for “Controller Area Network”. Its intended use is as a serial bus system
for a network of controllers. Each controller connected through a CAN chip is called a
"node" and is mostly used to acquire data from a sensor. All nodes are connected to a
common bus and all nodes are able to simultaneously read the data on that bus. Also,
all nodes are able to transmit data on that bus however only one node at a given time
has write access to the bus. If the message is relevant, it will be processed; otherwise
it is ignored. The unique identifier also determines the priority of the message. The
lower the numerical value of the identifier, the higher the priority.
The cable bus is a twisted pair of shielded wire. Data can be transmitted in blocks
from 0-8 bytes at a maximum transfer rate of 1 Mbit/s for networks up to 40 meters.
For longer network distances the maximum transfer rate must be reduced to 50 Kbit/s
for a 1 km network distance. CAN will operate in extremely harsh environments and
the extensive error checking mechanisms ensure that any transmission errors are
detected.
2.3 SYSTEM STRUCTURE

1. HC4900 Central Unit

2. CAN junction-box
3. IC4600 console
4. Pressure transducer
5. Length and Angle sensor
6. Length sensor
7. A2B
8. Wind speed

2.4 HC4900 CENTRAL UNIT

The HC4900
(mentor) safe load
indicator comprises
a central
microprocessor unit.
The system
components are
connected via CAN
bus.
2.4.1 Performance parameter of central unit

1. voltage supply：10~30 V DC
2. Digital input：4 circuits（0~30V , could be used as calculator）
3. PWM output：4 circuits（50-400 Hz, 2 A, current control or calibrated by digital
output port)
4. I/O port (configured)：4 circuits I/O
5. Housing：Aluminum metal board
6. system connector：M23×1, 19 poles socket
7. Protection grade：IP66
8. Dimension：181 × 141 × 70.5 mm (L × B × H)
9. working temperature：-30 °C to + 70 °C
10. Storage temperature：-40 °C to + 80 °C
11.CAN communication protocol：CANopen2.0B
12.CAN connector：M12×1, 5 poles socket
13. Relay：2 circuits (max. 4 A)
14.calibration port：RS 232
15.processer ：Motorola MPC 561, 40 MHz, 32bit, FPU
16. SRAM：2M
17. Flash-EPRAM：4M

2.4.2 Port configuration of central unit

HC 4900 central unit (also called mentor) is the CAN master of the system, in charge
of controlling the other node. It has the function of LMI calculation, port configuration;
management and control of CAN bus and so on.

Mentor central unit has nineteen ports among which there are four circuits of digital
input port, four circuits of input and output multiplexing port, four circuit of PWM and
output multiplexing port, two circuit of relay public port, two circuit of relay port, two
port of power input, one GND port.

Specific configuration as follow：

Port SN Port function Port SN port function Port SN port function

1 DIN0 8 PWMOUT0/DOUT0 15 K1_MK

2 DIN1 9 PWMOUT1/DOUT1 16 K1_AK

3 DIN2 10 PWMOUT2/DOUT2 17 K2_MK

 4 DIN3 11 PWMOUT3/DOUT3 18 K2_AK

5 DIN4/DOUT4 12 GND 19 UBS

6 UBP 13 DIN6/DOUT6

7 DIN5/DOUT5 14 DIN7/DOUT7

2.4.3 Port configuration for the application on XCMG telescopic crane

Port SN Wire color port function Application

1 green DIN0 Front and rear

2 orange DIN1 Half and full extended outrigger

3 white DIN2 Override input

4 white-red DIN3 Boom telescope out signal input

5 blue DIN4/DOUT4 Boom telescope in signal input

6 brown UBP 24V

7 purple DIN5/DOUT5 Free-slew signal input(only when use iflexc3)

8 white-orange PWMOUT0/DOUT0 red warning light output

9 white-yellow PWMOUT1/DOUT1 yellow warning light output

10 white-green PWMOUT2/DOUT2 green warning light output

11 white-blue PWMOUT3/DOUT3 Boom telescope control signal

12 yellow GND GND

13 black DIN6/DOUT6 Luffing lamp

14 grey DIN7/DOUT7 Telescope lamp

15 white-purple K1_MK 24V

16 white-black K1_AK Overload output

17 white-brown K2_MK 24V

18 black-red K2_AK Free-slew valve signal

19 red UBS 24V

2.4.4 Digital input port

DIN0: first circuit of digital input (bit0)

DIN1: second circuit of digital input (bit1)
DIN2: third circuit of digital input (bit2)
DIN3: fourth circuit of digital input (bit3)

Above four DIN can be defined as digital input port according to the program
requirement, such as front and rear checking, half and full extended checking, obliged
input checking and so on.

2.4.5 Digital output port

DIN4/DOUT4~~ DIN7/DOUT7 circuits could be used as digital input or digital output.

Please set not only the io.cfg files but also the jumper on main board when setting
digital output or input.

To be used as digital input：

DIN4: fifth circuit of digital input

(bit4)
DIN5: sixth circuit of digital input
(bit5)
DIN6: seventh circuit of digital input
(bit6)
DIN7: eighth circuit of digital input
(bit7)

To be used as digital output：

DOUT4: fifth circuit of digital output

(bit4)
DOUT5: sixth circuit of digital
output (bit5)
DOUT6: seventh circuit of digital
output (bit6)
DOUT7: eighth circuit of digital
output (bit7)

2.4.6 PWM output Port

PWMOUT0~ PWMOUT3 could be used as PWM output or digital output, which is set
at the IO port configuration.
When PWMOUT0~ PWMOUT3 port is used as PWM signal output：

PWMOUT0: first circuit of PWM output

PWMOUT1: second circuit of PWM output
PWMOUT2: third circuit of PWM output
PWMOUT3: fourth circuit of PWM output

When PWMOUT0~ PWMOUT3 port is used as digital output：

PWMOUT0:DOUT0
PWMOUT1:DOUT1
PWMOUT2:DOUT2
PWMOUT3:DOUT3
DOUT0: first circuit of digital output (bit0)
DOUT1: second circuit of digital output (bit1)
DOUT2: third circuit of digital output (bit2)
DOUT3: four circuit of digital output (bit3)

2.4.7 Power and ground Port

UBS: 24V power supply (power on first before system power on)
UBP: 24V power supply
GND: system ground

2.4.8 Relay Port

There are two relay K1\K2 for

extended usage on the main board
of mentor as useful port:

K1_MK: public port of relay 1

(COM)，could be connected with
24V voltage or ground

K1_AK: usual port of relay 1 (NO)

K2_MK: public port of relay 2

(COM)，could be connected with
24V voltage or ground

K2_AK: usual port of relay 2 (NO)

2.5 CAN JUNCTION BOX

CAN junction box just like a

CANbus concentration unit. Inside
of the box, there is a CAN patch
board with five socket which could
 be connected with five different
CAN nodes.

Every CAN equipment provide

power, ground, CAN_H, CAN_L
and shield signal（CAN_Shield）.
The CAN junction box is a CAN-bus
communication net collecting all the
signal of CAN equipment in system

2.6 IC4600 CONSOLE

Console: The IC4600 graphic

console displays all geometrical
information such as length and
angle of main boom, working radius
and head height of the boom. It also
displays the actual load and the
maximum load permitted by load
chart. Furthermore, it has an
alarm horn, a warning light for
overload, and a pre-warning light.
The graphic display allows for a
simple interactive configuration
setup, as well as sensor calibration
(zero adjustment), and
troubleshooting sensor output
screen. The console has a warning
light for anti-two-block conditions
and an override switch for overload
or anti-block condition.

2.6.1 Performance parameter of IC4600

Type In-dash
Housing sheet metal
Protection class
IP65
front
IP20
back
Supply Voltage 11…36 VDC
Processor 16-bit C167CS @20MHz
Program memory 2MB FLASH 1MB RAM
Data memory 16Kb FRAM Serial Memory
Real time clock ·
Watchdog ·
Cut-off Relay ─
Indicator & buzzer 3 LEDs and 1 buzzer
Digital Input ─
PWM Output ─
Digital Output ─

Dimensions(in mm)
front plate(W×H) 160×230 mm
cut-out/depth 136×210×68 mm
(W×H×D)

Display
QVGA(320×240)
pixel
5.7 inch256 colors
Size
LED backlight
Color

CANopen 2.0B
Serial interface
RS232
Operating temperature -20…+70℃
Storage temperature -35…+80℃
CoDeSys compatible ·
2.6.2 The information showing on the main interface

A B C

2 7 14

15

8
3 16

4 17

5
18
6 9
19
10 11 12 13
0 20

Warning light：
A. A2B warning light
B. Pre-warning light
C. Alarm light
The parameters of main interface：
1. Load moment bar and percent
2. OM code
3. Maximum lifting height of hoist up
4. Luffing angle of main boom
5. Working radius
6. Actual Load
7. Reeving number of hoist
8. The length of main boom
9. Rated Load
10. Slope Angle of
11. Counter weight number
12. Wind speed value
13. The status of outrigger (1/2 is half，2/2 is full）
14. Current time
Function key：
15. Press it to set some parameters
16. OM code set, press it to set the OM code
17. Reeving number set, press it to set the reeving number
18. Error code inquire key
19. Horn off key
20. Digital number key

2.6.3 Function operation

On the main interface，press the key correspond to the icon go to the Function set
interface, in this interface we could do the follow operations
 Language interchange between Chinese and English（press the corresponding key
directly）
 Units interconvert between Metric and Imperial（press the corresponding key directly）
 Set the maximum limit angle
 Set the minimum limit angle
 Set Time and Date
 Can-Bus State checking
 OM code explanation (Helper), through it you could get the detailed OM code that
you want to set.
 Cancel Angle Limit

2.6.4 ANGLE LIMIT

The LMI system could set the limitation of the boom angle to warn the operator of extreme
caution under dangerous condition: buildings, bridges, high-voltage wire etc.

注 意
This limit function is only of warning use but without control function. For
each time reset the LMI system you need to reset the limit value.
►Maximum angle limitation
According to the real situation，Luffing up the main boom to the maximum safe angle，press

key , the indicator area will display the angle, LMI record this angle as the maximum

STOP
limitation, when upper than the limiting value, indication light will light up and send
audible alarm sound to warn the operator to take extreme operation.

► Maximum angle limitation

According to the real situation，Luffing down the main boom to the maximum safe angle，press

key , the indicator area will display the angle, LMI record this angle as the minimum

STOP
limitation, when lower than the limiting value, indication light will light up and send
audible alarm sound to warn the operator to take extreme operation.

►Cancel angle limitation

Press digital number “4” to cancel the set value in function setting interface.
Time and Date set

Press the key and to choose the item you want to set, when the item being chosen,
the back color will change to blue from green; then input current time or date what you want by

press the corresponding digital number, the value you input is right please press to
confirm, if you find that you input a wrong value please press to make the value to be

zero and input again on a certain item, press to leave this interface.

2.6.5 CAN-Bus state

IC4600 display adopt the advanced Can communication technology and monitor status of
every node’s. If some node has communication error, you could judge which the error node is
through the interface of CAN-BUS status checking.

The node’s working state distinguished by different color:

 Green: operational
 Yellow: Pre-Operational
 Red: Error or not exist
2.6.6 OM code inquire

2.6.7 OM code setting

When start to operate the crane, please make sure the current OM code is right, if not please
set the code to be the same as the actual one.

Go to the Operating Mode Set interface by press in the main LMI interface.

Input the right OM code what you want by press the corresponding digital number, the value

you input is right please press to confirm, if you find that you input a wrong value please
press to make the value to be zero and input again, press to leave this interface.

2.6.8 Reeving setting

Reeving setting interface is used for setting the number of steel rope. Operator shall adjust the
displayed value same as the actual one before operation.

The relation of displayed reeving and actual reeving one-to-one like follow.
Console display：1——12
Number of steel cable ：1——12

Go to the Reeving Set interface by press in the main LMI interface.

Input the right OM code what you want by press the corresponding digital number, the value

you input is right please press to confirm, if you find that you input a wrong value please

press to make the value to be zero and input again, press to leave this interface.

2.6.9 Fault Help

Press the button on the main LMI interface to enter into the interface of error help. This
interface will explain what the error code means and offer you solution for maintenance and
usage.
Press the button and for checking error code and press the button for
turning back to main interface.

2.6.10 Horn off

Buzzer of IC4600 display will send out warning sound if the follow situations happen：
—— excess the max. Rated load moment
—— hook is closing to the height limit
—— excess the working range
—— LMI system error
—— wrong operation

Press the button on the interface to stop the warning sound 30S.

2.6.11 A2B indicating light

When the hook and pendant of A2B switch is touched and lifted, the red A2B indicating
light will light on and buzzer will sound at the same time, which means the hook is closing
to or reaching to the height limit. Then the operation of lifting hook, luffing downward and
extending boom will be forbidden. In order to avoid damage to machine and harm to
personnel, please check the A2B system before operation.

2.6.12 Pre-warning light

when the actual load moment reached to 90%～100% of the rated load
moment, the yellow pre-warning will light on the facial board will light on which
means the overload status is closing and operator shall pay more attention to.
2.6.13 Overload warning light
STOP
When the actual load moment reached to 100% of the rated load moment, the red “STOP”
warning will light and buzzer will sound. In addition, the light will light on when LMI system
is error and the operation of hook lifting, boom extending and luffing downward will be
forbidden. This status will be released when taking the operation of putting down load
or luffing upward.

2.7 PRESSURE TRANSDUCER

The pressure transducer converts

hydraulic pressure into an electric
signal. Every pressure transducer
has its own CAN bus converter
board, and it has own device
Node-ID. One pressure transducer
is connected to the piston side of
the lift cylinder, we call it piston oil
pressure transducer, its Node-ID is
0x3C; the other one is connected to
the rod side of the lift cylinder,
which we call rod oil pressure
transducer, its Node-ID id 0x3D.

There are five pins on the

transducer:

1 2 3 4 5

PE（shield） ＋UB 0V CAN_H CAN_L

The default baudrate is 125K

2.8 LENGTH AND ANGLE SENSOR

The Length-Angle Transducer:

The length-angle sensor (LWG),
often referred to as the “cable reel”,
is a combination of two transducers
in one box, installed on the base
section of the boom. It measures
the length and the angle of the
boom.

A reeling drum drives a

potentiometer, which is the length
 transducer. Part of the length
transducer circuit is the length
cable on the drum, which is a
multi-conductor cable. It is
connected to the anti-two-block
switch at the boom head and to a
slip ring body in the LWG, and lastly
connected to the CAN conversion
board, which is connected to the
bus system.

The angle transducer is a

potentiometer driven by a weighted
pendulum that is oil damped. Both
length and angle transducer are
connected to a CAN bus
conversion board, which is
connected to the bus system.

2.9 LENGTH SENSOR

The length sensor (LG), it is also

called as the “cable reel”, the
reeling drum drives a potentiometer,
which is the length transducer.

We are using current signal length

sensor, 4-20mA, when it is
connected in a whole CAN-BUS
system, it should be convert to CAN
signal by the CAN conversion
board inside the length and angle
sensor (the big cable reel)

2.10 A2B SWITCH

Anti-Two-Block Switch: The

anti-two-block switch monitors the
load block and its relationship with
the head of the boom. In working
condition the switch is closed.
When the load block strikes the
weight the circuit opens,
disengaging a relay output to the
 lock out solenoid valves, where
applicable. To check the cable for
damage, (short circuit to ground)
there is a 4.7k resistor between
ground and the contact of the
switch, to give a signal back to the
central unit. The weight at the
anti-two-block switch keeps the
switch closed until the load block
strikes it.

2.11 WIND SPEED

The wind speed (anemometer)

used to measure how large is of the
wind, it converts the wind into an
electric signal, the HC4900 system
support current and voltage signal
wind speed sensor, and we are
using current signal now. The
current signal also converted by the
CAN conversion board inside the
Length-Angle sensor (big cable
reel).
3 TROUBLE SHOOTING

3.1 LENGTH SENSING

The system measures the length of the main boom of the machine with a length
sensor. The length sensor is contained within the cable reel, located on the left side of
the main boom.

Block Diagram

Length CAN-Bus HC4900

Sensor Converter CU

CAN junction-box

Cable Reel

The signal runs from the length sensor to the CAN-Bus converter board, both located
in the cable reel. From there, it travels as digital information on the CAN-Bus to the
CAN junction box，which acts as the main CAN-Bus running to the central unit.

So, what do you do when you are having a problem with your length read-out?

X1 (CAN)

X20 (length)

CAN-Bus electronics in cable reel.

The length sensor has a potentiometer built in that is driven by a gear drive from the
cable drum. As the length changes, the cable drum will turn and with it the
potentiometer’s axle. The converter board supplies a voltage of about 4.7V to the
length potentiometer and in return monitors the output voltage of the potentiometer.
The terminal used is X20. The length sensor is connected as follows:

Terminal X20
1 + 4.71V
2 Signal
3 + 0.29V

The length potentiometer is 10K and 10 rings, it has three pins, the resistance
between pin1 and pin3 is constant, and equal to 10K, the resistance between pin1
and pin2 from 0 to 10K, and the resistance between pin2 and pin3 from 10K to 0.

When there is something wrong with the Length channel, please do the follow steps:

Option 1:
Option 2:

The length sensor returns a voltage between 0.29V at 0 turns of the length pot (= fully
retracted) and 4.71V at 10 turns. How many turns you get at full extension depends
on the gear ratio, the boom length, the length cable used and the spooling pattern, so
we cannot provide a standard table for it.

What we can give you for trouble-shooting, however is the following table that shows
the expected output voltage (measured between X20-2 and X20-3 Signal) for each
complete turn of the length potentiometer.
Length Sensor Signal on Pin 3
Resistance value
Turns Voltage X20-2 to X20-3 Voltage X20-2 to GND
between pin1 and pin2
0 0 0 0.29
1 1K 0.44 0.73
2 2K 0.88 1.17
3 3K 1.33 1.62
4 4K 1.77 2.06
5 5K 2.21 2.5
6 6K 2.65 2.94
7 7K 3.09 3.38
8 8K 3.54 3.83
9 9K 3.99 4.27
10 10K 4.42 4.71
Note: Actual voltages will vary slightly.

Length sensor zero point set

1. Fully retract the main boom

2. Open the cable reel’s cover
3. Turn the screw (look at the follow picture, focus the blue sign) of the length
potentiometer with a small screwdriver counter-clockwise to a soft stop, the
Length should be the same as the basic boom’s length, if not do the error
check

Correct LG limitation：
Please refer to the 9.1.4.
3.2 ANGLE SENSING

The System measures the angle of the main boom of the machine with an angle
sensor. The angle sensor is contained within the cable reel, located on the left side of
the main boom.

Block Diagram

Angle Sensor CAN-Bus HC4900

Converter CU

CAN junction-box

Cable Reel

The signal runs from the angle sensor to the Can-Bus converter board, both located in
the cable reel. From there, it travels as digital information on the CAN-Bus to the CAN
junction box, which acts as the main CAN-Bus running to the central unit.

So, what do you do when you are having a problem with your angle read-out?

X1 (CAN)

X21 (angle)

CAN-Bus electronics in cable reel

The angle sensor has a potentiometer built in that is driven by a pendulum. As the
angle changes, the pendulum will drive the potentiometer’s axle. The converter board
supplies a constant voltage of 5V to the angle sensor and in return monitors the
voltage of the potentiometer.

The terminal used is X21. The angle sensor is connected as follows:

Terminal X21
1 + 5V
2 Signal
3 GND
When there is something wrong with the Angle channel, please do the follow steps:

Option1:

Option2:
Note: If you need to determine the angle for voltages other than shown above, do so
by using the following formula:

Angle (degrees) = 90 degrees – ((Voltage-1.875) * 72)

Angle zero point set

1. Luffing down the main boom to zero degree

2. Open the cable reel
3. Use a hexagon wrench(6mm) to loose the screwdriver of sign B, use a
spanner(10mm) to loose the screwdriver of sign A, until could turn the angle
sensor!
4. Counter clockwise rotating will decrease the angle and clockwise rotating will
increase the angle, adjust the displayed angle to the same as the value measured
by angle device, and the error must not exceed ±0.2°
3.3 CAN CONVERSION BOARD

When CAN conversion stop working, master device (HC4900 mother board) can’t get
its heartbeat and will send error code E64, please check the length/angle sensor
cable, if the cable short-circuit or open-circuit, please replace the cable, if not replace
the CAN conversion board.

3.4 PRESSURE TRANSDUCER

In our HC4900 system, sometimes we use two pressure transducers for one crane,
sometimes only one, it’s depends on the crane’s hydraulic system.
Pressure transducer output CANbus signal, the digital value from 0 to 300, and the
value will be changed linear. When no oil pressure force on the transducer, it outputs
near 0, if the value over than 5 at the moment, you should change another pressure
transducer.
3.5 LENGTH SENSOR (LG105/11.5)

Usually we use this length sensor to measure the second boom’s length, to finish
boom telescope out sequence control.

This length sensor is current signal, from 4mA to 20mA, when the potentiometer at
zero position, it output 4mA, the fully out signal depends on the cable on the reel.

X1 (CAN)

LED

X22 (2st length)

3.6 A2B SWITCH

HC4900 system use 4.7KΩ/open-circuit A2B switch, central unit can check out
resistance value among 3.11KΩ to 8.1KΩ.

In working condition the A2B switch hang a weight, there is a 4.7KΩ resistant signal
between the plug’s pin2 and pin3, when hoist up and the hook strike the weight, A2B
switch will open-circuit, cut off the signal output!

In order to finish that the A2B of main and jib hook could working at the same time, we
must serial-connect the two A2B, otherwise parallel connection of a piece of 20K
resistance is necessary to reduce the value range of resistance.
When there is problem with the A2B, please do the follow steps:
3.7 WIND SPEED

The wind speed is current signal, the effective measurement range is 0~40m/s.

4mA ------ 0m/s

20mA ------ 40m/s

The wind speed signal also be convert by CAN conversion board which inside the big
cable reel (length/angle sensor), by monitor the PDB variable could get the digital
value.

Sampling Resistor of wind speed is 200Ω, so:

4mA ------ 0m/s ------ 0.8V

20mA ------ 40m/s ----- 4V

The standard sampling voltage is 5V, and 5V correspond to digital 32768, so:

4mA (0.8/5)*32768=5242.88
20mA (4/5)*32768=26214.4

X1 (CAN)

LED

X23 (wind speed)

If wind speed turns as normal, but not vary on display, please carry out the follow
check steps:
3.8 NO CONSOLE DISPLAY

If the console display all the information, just no warning light when in dangerous,
please replace the warning light board.

If the console has warning lights and back-lighting, but no any information showing on
the LCD, please replace the LCD screen.

If no light and no warning lights and no back-lighting, please follow the steps below

3.9 NO POWER IN CENTRAL UNIT

If no power supply to the sensors and display, please check the central unit and the
19-pins cable which connect to the CU.
3.10 CAN-BUS COMMUNICATION

The System measures the length of the main boom, the angle of the main boom, the
pressures of the lift cylinder, and the A2B state of the machine via a CAN-Bus
connection. Since this is a digital bus connection, it is not possible to measure the
signals on the bus with a multi-meter. Instead, the LMI provides you with error codes
that give you an indication of the bus state.

The error codes are one of the following:

E61 Error in the CAN bus data transfer for all CAN units
E62 Error in the CAN bus data transfer of the pressure transducer sensor unit
E63 Error in the CAN bus pressure transducer sensor unit
E64 Error in the CAN bus data transfer of the length/angle sensor unit
E94 Error in the CAN bus data transfer between the CU and Console

Block Diagram

Pressure Transducer

E63
E62 IC4600
CAN-Bus E64 E61 HC4900
E94 Console
CU
Converter

CAN junction box

Cable Reel

The block diagram tries to clarify that: If the CU does not see any CAN-Bus
component, it will report an E61. If it sees only the cable reel, it will report an E62
(pressure transducer missing). If it sees only the pressure transducer, it will report an
E64 (cable reel missing). E63 means that the pressure transducer is available, but is
reporting an internal error.

So, what do you do when you are having a problem with one of those codes?
3.10.1 E61

In case of an E61, it meaning that more than two CAN devices don’t send heartbeat,
or the CU could not read them, please monitor the PDB variables of all the sensor
devices’ heartbeat

 BYT115: length/angle sensor

 BYT160: piston pressure transducer
 BYT161: rod pressure transducer

If a sensor device working, its heartbeat status value must be equal to 5. When E61,
more than two sensor devices’ heartbeat equal to 0, record the error devices, check
the cable between CAN junction box and sensor device, if there is short or open
circuit with the cable, replace it; if not, replace the correspond sensor device.

Status definition
0 Boot-up
4 Stopped
5 Operational
127 Pre-operational

3.10.2 E62

The pressure transducer is also a CAN device, when it doesn’t work, its heartbeat
miss, the HC4900 system will show us error E62, but don’t distinguish is rod one or
piston one, we should judge it by ourselves, through monitor the PDB variable
BYT160 and BYT161 to check (which should use iTool5), if the correspond value is
not equal to 5, you should replace the pressure transducer or its cable.
3.10.3 E63

In case of an E63, the pressure transducer is reporting an internal problem. You

cannot troubleshoot any further, but need to replace the pressure transducer.

3.10.4 E64

In case of an E64, the CU is reporting no signal from the cable reel unit. Start by
change the plug position of cable with pressure transducer’s cable on CAN junction
box, if E62 occur, replace the CAN junction box; if not measure the cable from the
CAN junction box to the cable reel with an Ohm-meter. Check all pins of the CAN bus
cable for continuity and cross-check for short circuit.

If the continuity check fails, the cable must be replaced. If the cable appears to be
fine, next check the connector at the cable reel. You can verify that power is being
supplied to the sensor by testing the CAN connectors per the pin layout (see E61).
Replace the connector if this check fails.

If the connector checks properly, the board in the cable reel might be defective.
X1 (CAN)

X14 (A2B)

X20 (length)

X21 (angle)

LED
CAN-Bus electronics in cable reel.

X1 Pin CAN
1 CAN_SHLD
2 CAN +UB
3 CAN GND
4 CAN_H
5 CAN_L

3.10.5 E94

HC4900 CU send a message per a second to test the communication between CU

and console, if the console could not receive the message on time, it will show out
error code E94, but lots of problem cause the console can’t receive the message on
time.

 Short circuit between CAN_H and CAN_L

 CAN device’s communication disturb

4 SYSTEM COMMUNICATION CABLE

The communication cables among all the parts of system are:

the communication cable of central unit-CAN junction box,

the communication cable of console，

the cable of oil sensors, the cable of length/angle
sensor.

The lead line color of the cable is uniform: brown, white, blue, black, gray. The
soldering method between lead line and the tie-in of the lead line is also uniform：

1 Brown Shield

2 White CAN_V+

3 Blue CAN_GND
 4 Black CAN_H

5 Gray CAN_L

4.1 THE COMMUNICATION CABLE OF CONSOLE

One side of the cable is connected to CAN junction box, and another side is
connected to the console.

CAN Junction Box Terminal

4.2 THE CABLE OF PRESSURE TRANSDUCER

Pressure transducer terminal CAN junction box terminal

4.3 THE CABLE OF LENGTH/ANGLE SENSOR

Cable Reel Terminal CAN Junction box terminal

The pins soldered on the both terminals of length/angle cable are the same.

4.4 CALIBRATION CABLE OF LMI

The calibration cable of the LMI of 4900 central unit is 232COM communication cable.
Nine-core D type COM tie-ins are soldered on both sides. The connection method of
lead line is as following:
5 DRAWINGS

5.1 SYSTEM TOPOLOGY DIAGRAM

5.2 CENTRAL UNIT TO CRANE WIRING DIAGRAM

5.2.1 Earlier version

5.2.2 The latest version