Hirschmann MARK 4E/2 User manual

HIRSCHMANN
LOAD MOMENT INDICATOR SYSTEM
MARK 4E/2
01 12.0ft 40000lb
06 35.0ft 6800lb
SERVICE MANUAL
P/N 031-300-190-075 REV D 12/19/2008

Service Manual Mark 4E/2
©Hirschmann Rev. D 12/19/08 WG/SC 190075_D
NOTICE
Hirschmann, Inc. makes no warranty of any kind with regard to this material, including, but not limited
to, the implied warranties of merchantability and/or its fitness for a particular purpose.
Hirschmann, Inc. will not be liable for errors contained in this manual or for incidental or consequential
damages in connection with the furnishing, performance, or use of this manual. This document
contains proprietary information, which is protected by copyright, and all rights are reserved.
No part of this document may be photocopied, reproduced, or translated to another language without
the prior written consent of Hirschmann, Inc.
Hirschmann, Inc. reserves proprietary rights to all drawings, photos and the data contained therein.
The drawings, photos and data are confidential and cannot be used or reproduced without the written
consent of Hirschmann, Inc. The drawings and/or photos are subject to technical modification without
prior notice.
All information in this document is subject to change without notice.
MANUAL REVISIONS
REV DATE NAME DESCRIPTION
- 7/25/2002 SB Created service manual, ECN 02-205
A 9/15/2003 SB Add Console/Central Unit Connections, ECN 03-115
B 4/29/2008 SC ECN 08-071 (include PAT sensors & revise wiring)
C 10/10/2008 WG ECN 08-149 (revise wiring)
D 12/19/2008 WG ECN 08-204 (Wiring diagrams added to end of manual)
© 2008 Hirschmann Automation and Control, Chambersburg, PA 17201, USA

Service Manual Mark 4E/2
©Hirschmann Rev. D 12/19/08 WG/SC 190075_D
TABLE OF CONTENTS
1MECHANICAL DESCRIPTION OF THE COMPONENTS .................................................1
2MECHANICAL AND ELECTRICAL DESCRIPTION OF THE CENTRAL UNIT ................2
3BASIC ADJUSTMENT OF THE HARDWARE ..................................................................3
4DEFINITIONS ....................................................................................................................4
5DRAWINGS .......................................................................................................................5
5.1 WIRING DIAGRAM -CENTRAL UNIT SHUT OFF............................................................................. 5
5.2 CENTRAL PROCESSOR 12/24 VDC........................................................................................ 6
5.3 ELECTRICAL DIAGRAM –CENTRAL UNIT/CONSOLE.............................................................. 7
5.4 INDICATOR PANEL/CONSOLE 1-0118417.00 SPARE PARTS LIST ................................................ 8
5.5 ELECTRICAL DIAGRAM –CABLE REEL /A2B SWITCH ....................................................... 8
5.6 CABLE REEL PARTS LIST ............................................................................................................ 9
5.7 ANTI-TWO BLOCK SWITCH (PAT)........................................................................................ 10
5.8 ANTI-TWO BLOCK SWITCH (KUEGER) ..................................................................................... 11
5.9 PRESSURE TRANSDUCER (250 BAR): 1-0108060.00 ............................................................... 12
5.10 PRESSURE TRANSDUCER CABLE ASSEMBLY ......................................................................... 12
5.11 PRESSURE TRANSDUCER (DAVS300 /3401)........................................................................ 12
5.12 CABLE ASSEMBLY (PRESSURE TRANS), 031-300-060-693.................................................... 13
5.13 JUMPER CABLE ASSEMBLY FOR EXTENSION,031-010-100-144 ............................................ 14
5.14 ROLLER SWITCH WIRING,031-006-100-043.......................................................................... 14
6LENGTH AND ANGLE SENSOR ADJUSTMENT...........................................................15
6.1 EPROM REPLACEMENT IN CENTRAL UNIT .................................................................................. 16
6.2 PISTON &ROD PRESSURE CHANNEL ADJUSTMENT ................................................................... 17
6.2.1 Adjust pressure piston: ................................................................................................... 17
6.2.2 Adjust pressure Rod: ...................................................................................................... 17
6.3 LENGTH CABLE REPLACEMENT ................................................................................................ 18
7TROUBLESHOOTING FLOW CHARTS .........................................................................19
7.1 GENERAL FLOWCHART ...................................................................................................... 19
7.2 LEVER LOCKOUT ACTIVATED ............................................................................................ 20
7.3 BLANK DISPLAY ................................................................................................................... 21
7.4 ANTI-TWO-BLOCK PROBLEM.............................................................................................. 23
7.5 LENGTH READING PROBLEM ............................................................................................. 26
7.6 ANGLE READING PROBLEM ............................................................................................... 27
8ERROR CODES .............................................................................................................. 28
8.1 OPERATOR ERROR CODE TABLE...................................................................................... 28
8.2 SYSTEM ERROR CODE TABLE ........................................................................................... 30
9TROUBLESHOOTING MOISTURE.................................................................................32
9.1 WATER INGRESS...................................................................................................................... 32
9.2 CONDENSATION ....................................................................................................................... 33
10 LMI SYSTEM TEST PROCEDURE .................................................................................34
11 APPENDIX....................................................................................................................... 35

Mechanical Description Of The Components
©Hirschmann Rev. D 12/19/08 WG/SC 190075_D
1
1 MECHANICAL DESCRIPTION OF THE COMPONENTS
Pressure Transducer:
The pressure transducer transforms hydraulic pressure into an electric analogue voltage signal. Two
pressure transducers are connected, one to the rod side and one to the piston side of the lift cylinder.
The pressure transducer is connected to the central unit with a four conductor, double shielded cable.
The power supply voltage is +12V.
The output signal is 4.00ma at 0 pressure to 20.00ma at maximum pressure (300bar).
Cable Reel:
The cable reel houses the length-angle transducer, slip ring disc and slip ring pick up (to feed and
return A-2-B signal). The PE cable goes through the drum and out to the tip where it is wired to the
Anti-Two-Block switch. The reel is driven by a tensioned spring and should be handled with caution.
The Length-Angle Transducer:
The length-angle sensor (LWG) is a combination of two transducers in cable reel, fitted at the base
section of the boom. It measures the length and the angle of the boom. A reeling drum drives a
potentiometer, which is the length transducer. Part of the length transducer is the length cable on the
drum, which is a two-conductor cable (shield and core). It is connected to the anti-two-block switch at
the boom head and to a slip ring body in the LWG. The angle transducer is fitted in the cable reel. A
pendulum drives the axle of the angle potentiometer.
The power supply voltage for both is +12/24 vdc
The output signal for the length transducer is: 4.00ma up to 20.00ma
The output signal for the angle transducer is: 4.00ma at 90° to 20.00ma at 0°
Anti-Two-Block Switch:
The anti-two-block switch monitors the load block and its relationship with the head of the boom. In
working condition, the switch is closed with a 4.7k ohm resistor in series. When the hook block strikes
the weight the circuit opens, disengaging a relay output to the lock out solenoid valves, where
applicable. The weight at the anti-two-block switch keeps the switch closed until the hook block
strikes it.
Console:
The console displays all geometrical information such as length and angle of main boom and working
radius. It also displays the actual load and the maximum load permitted by load chart. Furthermore, it
has an alarm horn and a warning light for overload, and a pre-warning light. The LED’s instrument
shows a percentage of the total permissible moment. The console has pushbuttons to switch the
operating modes (for selection of crane configurations and reeving of the block). It also has a warning
light for overload, anti-two-block conditions and an override push-button for anti-two-block condition.

Service Manual
MARK 4E/2
©Hirschmann Rev. D 12/19/08 WG/SC 190075_D
2
2 MECHANICAL AND ELECTRICAL DESCRIPTION OF THE CENTRAL
UNIT
All data of the crane are stored inside the central unit in EPROMs. The central unit gets all actual
information of the crane. This is computed against the reference data and the crane status
continually monitored.
Description of the Housing:
The MARK 4E/2 central unit has a water proof aluminum housing. It is mounted on the left side of the
turntable weldment or on the counterweight. The cables are led into the central unit via strain reliefs
and connected with fast-ons. An override switch is mounted on the housing to override the LMI
function. The system is protected by a 2-AMP fuse that is mounted on the lower right side.
Description of the Boards:
Inside the central unit there is one board. The main board that has terminal strips where power and
various components are connected with fast-ons to the terminal strip. The main board is the heart of
the system. It contains the main computer and the necessary electronics to receive, evaluate, process
and direct the continuous data. There are overload and anti-two-block relays, which control the Bosch
relay for lever lockout, also mounted on this board.
A 24/12 volt converter, (for 24 volt cranes) which converts 24 volts to 12 volts on the main board.
An analogue input part, which receives and prepares all the signals from the transducers for further
processing.
An analogue/digital converter part , which converts all the processed analogue signals into digital
ones.
A digital part , which contains the main computer and the ancillary electronics.
Incoming Signals:
The signals from the transducers are connected to the terminal board. The signals of the angle-length
transducer are connected to terminal #56 (angle) and terminal #53 (length).
The signal on terminal #56 (angle) is between approximately 20.00ma to 4.00ma.
The signal on terminal #53 (length) is between 4.00ma and 20.00ma.
The signals from the pressure transducers are connected to terminal #52 (rod side) and terminal #51
(piston side). The signals on terminals #51 and #52 range between 4.00ma and 20.00ma.
The signal from the force transducer is connected to the terminals #51 and #52 range between4.00ma
and 20.00ma. The supply voltage +12vdc for the anti-two-block switch is terminal #72 and return
signal on terminal #71.
Outgoing Signal:
The outgoing signal of the terminal board is the signal for lever lockout of terminal #87 on the Bosch
relay. In normal working conditions there are 12 or 24 volts at this terminal. When there is an
overload or anti-two-block condition the signal becomes 0 volts. Furthermore, all voltages for the
transducers and console are going out via the terminal strip.

Basic Adjustment of Hardware
©Hirschmann Rev. D 12/19/08 WG/SC 190075_D
3
3 BASIC ADJUSTMENT OF THE HARDWARE
Length:
Ensure that the length cable tension is correct with fully retracted boom by turning the cable reel 2 to
check that the reel fully retracts. Then remove cover from cable reel and adjust the potentiometer till
fully counter clockwise to the soft stop.
Angle:
Set the boom to 0 degrees and set a digital level on the boom. Adjust the angle sensor to the same
angle as the boom. Check the angle at 20 degrees, 45 degrees, 70 degrees. Angle display should be
less than r.2 degrees of the value of the inclinometer.
Pressure Channel:
Rest the boom and disconnect the pressure transducers. Measure the voltage of both pressure
transducers on the terminal board. The output voltage of the pressure transducers should be 4.00ma.
Check the function of the hoist limit switch (anti-two-block)
Check function of lever lockout.
Measure and record the power supply voltages.

Service Manual
PRS145
©Hirschmann Rev. D 12/19/08 WG/SC 190075_D
4
4 DEFINITIONS
BOOM LENGTH The straight line thru the centerline of boom pivot pin to the centerline of the boom
point load hoist sheave pin measured along the longitudinal axis of the boom. (Indicator r2%)
BOOM ANGLE The angle between the longitudinal centerline of the boom base section and the
horizontal plane. (Indicator 65° to 90° boom angle + 0°/2°; less than 65° boom angle + 0°/-3°)
RADIUS OF LOAD The horizontal distance from a vertical projection of the crane’s axis of rotation to
the supporting surface, before loading, to the center of the vertical hoist line or tackle with rated load
applied. (Indicator 100% to 110%)
RATED LOAD The load value shown on the applicable load ratings chart of the crane for the particular
crane configuration, boom length, boom angle, or functions or these variables. For radii outside those
shown on the load ratings chart, the rated load is to be considered as zero.
ACTUAL LOAD The weight of the load being lifted and all additional equipment such as blocks, slings,
sensors, etc. Also referred to as working load. (Indicator 100% to 110%)
CRANE CONFIGURATION The physical arrangement of the crane as prepared for a particular
operation in conformance with the manufacturer’s operating instructions and load rating chart.
TWO-BLOCKING Contact of the lower load block or hook with the upper load block, boom point, or
boom point machinery.
ANALOGUE Electrical signals that vary in proportion to the quantities they represent. (Boom length,
angle, and pressure transducer)
DIGITAL Electrical signals of an on-and-off-state (two different voltage levels) to represent some
quantity of operation. (A2B, area definition switch)

Drawings
©Hirschmann Rev. D 12/19/08 WG/SC 190075_D
5
5 DRAWINGS
5.1 WIRING DIAGRAM - CENTRAL UNIT SHUT OFF
WARNING: The connection to the ground must
be as short as possible!

Service Manual
MARK4E/2
©Hirschmann Rev. D 12/19/08 WG/SC 190075_D
6
5.2 CENTRAL PROCESSOR 12/24 VDC
1-0116440.00 Spare Parts List
2.1
2
1
ITEM DESCRIPTION QTY PART NUMBER
1 Housing 1 1-0103719.00
2 P.C. Board (Central Processor) 1 1-0116073.00
3 Module (DC/DC Converter) 1 1-0028174.00
4 Key Switch 1 1-0103247.00
4

Drawings
©Hirschmann Rev. D 12/19/08 WG/SC 190075_D
7
5.3 ELECTRICAL DIAGRAM – CENTRAL UNIT/CONSOLE

Service Manual
MARK4E/2
©Hirschmann Rev. D 12/19/08 WG/SC 190075_D
8
5.4 INDICATOR PANEL/CONSOLE 1-0118417.00 SPARE PARTS LIST
35
1
24
SYSTEMTECHNIK
6/6.1
ITEM DESCRIPTION QTY PART NUMBER
1 Housing 1 1-0116046.00
2 Membrane Push Button 1 1-0118389.00
3 Buzzer 1 1-0012135.00
4 U-Shackle 1 1-0116059.00
5 Mounting Knob 2 1-010667800
6 P.C. Board 1 1-0115673.00
6.1 LCD-Matrix-Display 1 1-0114234.00
5.5 ELECTRICAL DIAGRAM – CABLE REEL / A2B SWITCH
(BLK) 1
031-002-060-014
(BLK) 1
not used
(RED) 3
(BRN) 2
1
2
3
4
5
6
(BRN) 2 (RED) 3
6 Pin Plug - Extension
A2B Switch
Dummy Plug for
Main Boom only
2
1
3
5
4
6
3
1
2
6
4
5
6 Pin Receptacal
Boom Tip
A2B Switch
(RED) 3 (BRN) 2 (BLK) 1
031-002-060-011
TOP
BRN
BOTTOM
CORE
RED
SHIELD
2
2
L
A
Cable Reel
068-308-060-001
1
2
3
4
6
5
7
1
2
3
6
5
4
8
7
+12VDC
L-Sig.
GND
A-Sig.
A2B Power
+12VDC
A2B Signal-
closed = +12V
1
4...20mA4...20mA
2
3
Shield
Core
1
1
Central Unit
1-0116440.00

Drawings
©Hirschmann Rev. D 12/19/08 WG/SC 190075_D
9
5.6 CABLE REEL PARTS LIST
6
6
8
10
3
1
11
2
7
4
5
9
6

Service Manual
MARK4E/2
©Hirschmann Rev. D 12/19/08 WG/SC 190075_D
10
DRAWING 5.5 CABLE REEL - PARTS LIST - continued
CABLE REEL ASSEMBLY, PARTS LIST
PART NO. PAT 068-308-060-001
NO. PART NO QTY DESCRIPTION
01 068-000-300-060 1 BOARD, TERMINAL W/ EMC FILTERS
02 064-103-060-007 1 ANGLE SENSOR WG103/0007
03 068-000-300-018 1 LENGTH POTENTIOMETER UNIT
04 002-050-206-012 2 SCREW M6 X 12 HEX SOCKET CAP
05 000-207-010-064 2 WASHER M6 FLAT
06 068-000-100-152 1 HOUSING KT200
07 000-214-340-013 1 PG13.5 HOLE PLUG
08 000-673-020-002 139’ CABLE, LENGTH SINGLE CORE
09 002-148-131-013 1 STRAIN RELIEF, PG13.5 RED/WHT
10 031-300-100-206 1 CHEMICAL, CORROSION INHIBITOR
11 068-000-100-064 1 SLIP RING ASSEMBLY 2 POLE
5.7 ANTI-TWO BLOCK SWITCH (PAT)
031-002-060-011 - main boom (with 12’ cable)
031-002-060-014 - jib (with 32’ cable)

Drawings
©Hirschmann Rev. D 12/19/08 WG/SC 190075_D
11
5.8 ANTI-TWO BLOCK SWITCH (KUEGER)
1-0024849.00 Spare parts List
ITEM DESCRIPTION QTY PART NUMBER
1 Center Housing 1 1-0112531.00
2 Cover - Left 1 1-0010045.00
3 Cover – Right 1 1-0010044.00
4 Slotted Flat Head Screw - M5 x 8 2 1-0013391.00
5 Lever 1 1-0010041.00
6 Straight Pin 1 1-0010042.00
7 Bushing 1 1-0010104.00
8 Spring 1 1-0100326.00
9 Micro Switch 1 1-0010039.00
10 Cable Connector 1 1-0010037.00
11 Blind Plug 1 1-0010038.00
12 Shackle with Cotter Pin 1 1-0009999.00
Required for Mounting - Order Separately
DESCRIPTION QTY PART NUMBER
Weld Plate 1 1-0010046.00
Hex Head Cap screw - M8 x 50 2 1-0010083.00
Lock Washer - M8 2 1-0010097.00

Service Manual
MARK4E/2
©Hirschmann Rev. D 12/19/08 WG/SC 190075_D
12
5.9 PRESSURE TRANSDUCER (250 BAR): 1-0108060.00
5.10 PRESSURE TRANSDUCER CABLE ASSEMBLY
(Part Number is depends cable length)
Connector Cable - Straight x 7M. 1-0114293.00
Connector Cable - Straight x 10M. 1-0114294.00
Connector Cable - 90qConnector 1-0101758.00
5.11 PRESSURE TRANSDUCER (DAVS300 / 3401)
Part Number 031-300-060-453 (4.20mA, 300 bar, M12, 9/16-18)

Drawings
©Hirschmann Rev. D 12/19/08 WG/SC 190075_D
13
Analog Input 2 Analog Input 1 GND GND
3 - BLK (Piston Trans.)
3 - BLK (Rod Trans.)
41 42
2 - BLU (Piston Signal)
51
2 - BLU (Rod Signal)
52
GND
+12 VDC
GND
X1.
+UDC
123456
1 - BRN (Piston.)
1 - BRN (Rod)
+12VDC
1178 109
+12VDC
12
(+24 VDC)
Crane Voltage
-refer to Crane DWG.-
MARK4 E/2 CENTRAL UNIT
Piston Pressure
Transducer 300bar
031-300-060-452
Cable assembly 031-300-060-693
Cable assembly 031-300-060-693
Rod Pressure
Transducer 300bar
031-300-060-452
3 SS
3 SS
not used
Signal
4...20 mA
+12 VDC
4
2 - BLU
1 - BRN 1
3 - BLK
2
3GND
not used
Signal
4...20 mA
+12 VDC
4
2 - BLU
1 - BRN 1
3 - BLK
2
3GND
5.12 CABLE ASSEMBLY (PRESSURE TRANS), 031-300-060-693
Pressure Transducer and Cable Assembly connection in Central Unit:

Service Manual
MARK4E/2
©Hirschmann Rev. D 12/19/08 WG/SC 190075_D
14
Central Unit
1-0116440.00
5.13 JUMPER CABLE ASSEMBLY FOR EXTENSION, 031-010-100-144
5.14 ROLLER SWITCH WIRING, 031-006-100-043