RaycoWylie i4000 User manual

Instruction Manual
i4000
Excavator Rated Capacity Limiter and Range
Limiting System
Copyright © 2019
RaycoWylie Systems
All rights reserved.
Wylie Systems
(Rayco Technology Group)
201 Prospect Avenue
Suite 106 - box 159
Hagerstown, MD 21742
USA
Tel: [phone]
Fax: [phone]
Rayco Electronic Systems
(Rayco Technology Group)
2440 Dalton Avenue
Ste-Foy, Qc
CANADA
G1P 3X1
Tel: [phone]
Fax: [phone]
Wylie Systems
(Rayco Technology Group)
Drury Lane
St-Leonards on Sea, East Sussex
ENGLAND
TN38 9BA
Tel: [phone]
Fax: [phone]
55M4000UBE00-A
Rev: MLF April 2019

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i4000 RCL For Excavator Instruction Manual
55M4000UBE00-A
The purpose of this manual is to provide the customer with the operating procedures
essential for the promotion of proper machine operation for its intended use. The
importance of proper usage cannot be overstressed. All information in this manual
should be read and understood before any attempt is made to operate the machine.
Since the manufacturer has no direct control over machine application and operation,
conformance with good safety practice in this area is the responsibility of the user and
his operating personnel.
All procedures herein are based on the use of the system under proper operating
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of the equipment are strictly forbidden without written approval from RaycoWylie
Systems.
The i4000 RaycoWylie Systems Excavator Information Center must be regarded
only as an aid to the operator. When the parameters are set correctly, the indicator
will warn the excavator operator of an approaching overload condition that could cause
damage to equipment, property, and/or injury to the operator or site workers in the
vicinity of the excavator and its load.
This system must never be used, under any circumstances, as a substitute for the good
judgment of a excavator operator when carrying out approved excavator-operating
procedures. Responsibility for the safe operation of the excavator lies with the excavator
operator. The indicator equipment will not necessarily prevent excavator damage due
to overloading and related causes if not set properly.
Before operating a excavator equipped with a RaycoWylie system RCI, the
operator must carefully read the information in both this manual and the excavator
manufacturer operator’s manual. He must also be aware of all the federal, state and
local safety standard and regulations applicable to his job. Correct functioning of the
system depends upon routine daily inspection.
Any suspected faults or apparent damage should be immediately reported to the
responsible authority before using the excavator.

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i4000 RCL For Excavator Instruction Manual
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Since the personnel’s safety and the appropriate use of the machinery
are a priority, different symbols are used in this manual to highlight
important points.
7KH IROORZLQJ GHÀQLWLRQV LQGLFDWH WKH OHYHO RI ULVN HDFK V\PERO
represents. Each time you see one of these symbols in this manual, the
operator’s safety or the machinery’s integrity are concerned.
3OHDVHWDNH\RXUWLPHWRUHDGDQGXQGHUVWDQGWKHVHGHÀQLWLRQV
NOTE: PROVIDES INFORMATION WHICH CAN BE OF
SPECIAL INTEREST.
DANGER: INDICATES A POTENTIALLY DANGEROUS
SITUATION WHICH, IF NOT AVOIDED, COULD RESULT
IN A PERSON’S DEATH OR IN SIGNIFICANT DAMAGE
TO THE MACHINERY.
ATTENTION: INDICATES A POTENTIALLY DANGEROUS
SITUATION WHICH, IF NOT AVOIDED, COULD RESULT
IN MINOR OR MODERATE DAMAGES. IT CAN BE USED
TO WARN ABOUT UNSAFE PRACTICES.
IMPORTANT: INDICATES A SITUATION WHICH COULD
DAMAGE THE MACHINERY.

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i4000 RCL For Excavator Instruction Manual
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CONTENTS
Warning page3
1 - GENERAL DESCRIPTION OF THE SYSTEM page 9
1.1 Introduction page 9
1.2 Operator skill page 9
1.3 Usefulness of the i4000 system page 9
1.4 Description of the i4000 system page 10
1.4.1 Audible alarm page 11
1.4.2 Visual alarm page 11
1.5 Location and description of typical components page 12
1.6 Overall scheme page 13
1.7 Technical information page 14
2 - DETAILED DESCRIPTION OF THE DISPLAY UNIT page 15
2.1 Overview of the display unit page 15
2.2 Description of operation keys page 16
2.3 Duty selection tab page 17
2.4 Lifting tab page 18
2.5 Range limiting tab (optional) page 18
2.6 Tools tab page 19
3 - INSTALLATION AND CALIBRATION page 23
4 - OPERATING INSTRUCTIONS page 25
4.1 Safety recommendations page 25
4.2 Residual risks page 26
4.3 Power-up page 27
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4.4.2 Selecting the measuring unit page 29
4.4.3 Selecting the language page 30
4.4.4 Selecting the night light intensity page 31
4.4.5 Adjust system data and time page 32
4.5 Duty selection page 33

55M4000UBE00-A
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i4000 RCL For Excavator Instruction Manual
CONTENTS
5 - RATED CAPACITY LIMITER page 35
5.1 Enabling/Disabling the lifting mode page 35
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6 - RANGE LIMITING SYSTEM page 37
6.1 Enabling/Disabling the range limiting mode page 38
6.2 Height limit page 39
6.3Slewlimit page40
6.4 Slew and variable height page 41
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6.6 Slew and variable radius limit page 45
7- DIAGNOSTIC AND MAINTENANCE page 47
7.1 Diagnostic menu page 47
7.2 Angle and Length sensor page 49
7.3Loadsensor page50
7.4 Slew sensor (Option of the range limiting device) page 51
7.5 Relay board page 52
7.6 Software information page 53
7.6.1 System data page 53
7.6.2 Load data page 54
7.6.3 Correction load page 54
7.7 Detected addresses page 55
7.8 Error messages page 55
7.8.1 Internal peripherals page 55
7.8.2 External peripherals page 56
8 - INSPECTIONS AND MAINTENANCE page 59
8.1 Frequent inspections page 59
8.2 Periodic inspections page 59
8.3 Checking the displayed load page 60
8.4 Maintenance page 61
8.5 Maintenance procedure page 62
8.6 Adjustments and repairs page 63

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i4000 RCL For Excavator Instruction Manual
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-1-
General description of the system
1.2 Operator skill
1.3 Usefulness of the i4000 system
The i4000 system shall prevent the excavator from supporting a load outside
the limits of the permitted radius and outside the loads shown and described on
the rated capacity chart or the permissible working load of the ropes when set
and operated correctly.
This manual contains information regarding the operation, troubleshooting, and
maintenance procedures of the i4000 system. Please make sure you respect the
safety rules currently in force in the country where you are using the i4000 system,
in order to reduce the risk of injuries or of damages to the machinery. Please
consider each safety directive mentioned in this manual when using the i4000
V\VWHP7KLVPDQXDOZLOOKHOSTXDOLÀHGSHUVRQQHOXVHWKHV\VWHPDQGSHUIRUPLWV
maintenance.
1.1 Introduction
The i4000 system shall be operated only by personnel without limitations in the
physical abilities of the upper limbs and no visual or hearing impairment, who
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and fully understood the instructions in this manual. Operator requirements
shall include: demonstrating the ability to read, write, comprehend, use
arithmetic, read and understand the load / capacity charts in the language of the
excavator manufacturer’s operating instruction materials. Maintenance of the
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55M4000UBE00-A
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i4000 RCL For Excavator Instruction Manual
1.4 Description of the i4000 system
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DLG,WFRPSULVHVVHQVRUVÀWWHGWRWKHH[FDYDWRUDQGDGLVSOD\ORFDWHGLQWKHFDELQ
of the excavator. This version measures the boom cylinder pressure, the boom
angle and the stick angle to indicate safe or critical conditions, while performing
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slew angle to provide some extra information to the operator. All the sensors are
linked through a single CAN bus (Controlled Area Network).
The pressure sensors provides electrical signals that are proportional to the actual
pressure in the hydraulic boom cylinder system of the excavator. Inclinometers
provides a signal that is proportional to the boom and stick angles. The radius and
the load are calculated from these signals with the dimensional excavator data pre
programmed in the i4000 system.
During operation the load lifted by the excavator is calculated from the measured
boom cylinder pressure and is automatically compared with corresponding data
related to the maximum permissible excavator loading. (Load charts)
The actual load is expressed as a percentage of the permitted load (% SWL). If this
percentage exceeds a preset value, alarms and safety functions are activated. The
values of the hook load, the permissible load (SWL), the lifting point height and
the radius are displayed in a digital form on a graphic liquid crystal display (LCD).
,I WKH DGGLWLRQDO VOHZ VHQVRU LV ÀWWHG WKHQ VRPH LQIRUPDWLRQ DERXW WKH FXUUHQW
slew angle will also be available. The required duty charts are stored in a non-
volatile memory and FDQRQO\EHPRGLÀHGZLWKWKHDSSURYDORIWKHH[FDYDWRU
manufacturer.
The calculated machine parameters and calibration data are stored in an additional
non-volatile memory. The calibration of the system is performed only with the use
of known loads, boom angles, and other pre-determined data.

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i4000 RCL For Excavator Instruction Manual
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If you are wearing hearing protectors or
headphones during lifting operations, make sure
they do not impair your ability to hear the
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1.4.2 Visual alarm
The i4000 system display has been equipped with a 3-colour warning light to alert
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alarm when the load reaches the approach alarm’s threshold, that is, 90% of the
nominal capacity. This is the default value and it can be changed in the calibration
menu.
The light turns red when 100% of the nominal capacity is reached or exceeded and
the audible alarm is continuous.
1.4.1 Audible alarm
An intermittent audible alarm within the display unit warns the
excavator operator that an intervention is necessary before the load
reaches its nominal value. The default threshold for the approaching
alarm is 90% of the nominal capacity. The overload alarm is activated continuously
when 100% of the nominal capacity is reached or exceeded. The excavator operator
will also be warned by the internal audible alarm when approaching or reaching a
OLPLWWKDWKDVDOUHDG\EHHQGHÀQHG
WARNING LIGHT
YELLOW REDGREEN
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to the user’s preferences.
W
W
W
W
1.4 Description of the i4000 system (continued)

55M4000UBE00-A
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i4000 RCL For Excavator Instruction Manual
1.5 Location and description of typical components
1. i4000 display system: It is also the central processing unit (CPU) of the
system. Its principal feature is a CAN Bus communication interface and
graphical LCD screen.
2. Central I/O interface: This relay interface module is connected to
individual external I/O devices to be controlled or monitored by the i4000
system.
3. 6OHZVHQVRURSWLRQDO: A slew sensor is used to determine the position
of the boom for the range limiting and/or to determine the load chart
selection.
4. Angle sensor: An angle sensor is used to measure the Boom angle.
5. Angle sensor: Another angle sensor is used to measure the Stick angle.
6. Pressure sensor: 3 Pressure sensors are used to determine the weight of
the load being lifted by measuring the pressure in the lifting cylinder.

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i4000 RCL For Excavator Instruction Manual
55M4000UBE00-A
1.6 Overall scheme
i4000
Display
Alimentation
12-30 VDC PWR
USB
CAN
I/O
ETH
- Soware programming
- Calibration exporting and programming
- Chart exporting and programming
- Event recorder exporting
1x HDIN
1x HDOUT
10/100 Mbps
Angle (Boom)
Slew (33S0047)
Capteurs de pressions (3 max.)
I/O Interface
Not available on the
normal version. It is
available for special
projects.
HDIN :
Chart selecting
(replacing 33S0047)
External Bypass
HDOUT :
Distinctive braking
Angle (Stick)
Angle (Split boom)
(Optional)

55M4000UBE00-A
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i4000 RCL For Excavator Instruction Manual
1.7 Technical information
Accuracy: In accordance with SAE J159
Operating temperature: -20°C to +70°C
Extended temperature: -40°C to +70°C
Power supply: 10-30 VDC (maximum power supply)
Display unit dimensions: 3.5’’ Crystal liquid screen (320 x 240)
Display unit protection: IP67
Bus CAN interface/ sensors: Default
quantity
Maximum
quantity
-Load or pressure sensors 3 3
-Angle or length sensors 2 3
- Relay output 1 1
- Rotation sensor 1 1
- Possibility of additional sensors NO

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i4000 RCL For Excavator Instruction Manual
55M4000UBE00-A
-2-
Detailed description of the display unit
 2YHUYLHZRIWKHGLVSOD\XQLW
WARNING LIGHT
(3 COLORS)
INTEGRATED
AUDIBLE
INDICATOR
GRAPHICAL
DISPLAY
MULTIFUNCTION
KEYS
WARNING LIGHT
When working in normal conditions, the light is green. It turns to yellow when
approaching a limit and turns red to alert the operator that a limit has been
reached.
GRAPHICAL DISPLAY
The Liquid Crystal Display allows access to multiple tabs and options to control
the i4000 system.
MULTIFUNCTION KEYS
Each key has a different function depending on the current mode. In other words,
the activated function when pressing a multifunction key will vary according to
the menu or window you are in.
FUNCTION DESCRIPTION

55M4000UBE00-A
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i4000 RCL For Excavator Instruction Manual
2.2 Description of operation keys
UP KEY
Press this key to scroll up through the options of the main
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DOWN KEY
Press this key to scroll down through the tabs of the
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value.
BACK KEY
Press this key to leave a menu or settings window,
and to return to the previous screen without saving
the changes. Press several times to return to the main
menu.
RIGHT KEY
Press this key to scroll right through the tabs of the main
menu or, in editing mode, to move on to the next digit of
DFRQÀJXUDEOHYDOXH
LEFT KEY
Press this key to scroll left through the tabs of the main
menu or, in Edit mode, to return to the previous digit of
DFRQÀJXUDEOHYDOXH
CONFIRM KEY
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accept new values in the system.

17
i4000 RCL For Excavator Instruction Manual
55M4000UBE00-A
2.3 Duty selection tab
This tab will show every information relative to the current duty selected. The duty
will automatically switch to the correct duty corresponding to the current sensor
YDOXHV6RPHRSWLRQVFDQEHPRGLÀHGGHSHQGLQJRQWKHDYDLODEOHDWWDFKPHQWVLQ
WKHFKDUWÀOH,IWKHFKDUWÀOHFRQWDLQVWZRGLIIHUHQWEXFNHWV\RXPXVWVHOHFWWKH
appropriate one in this window.
Duty
Tab
Parameters selection in the duty menu changes according to excavator
type and options programmed in the load chart.

55M4000UBE00-A
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i4000 RCL For Excavator Instruction Manual
2.4 Lifting Tab
This tab contains 3 different windows accessible by pressing the UP/DOWN keys.
2.4.1 Safe working load gauge (1 of 3):
A simple gauge shows the current safe working load (%SWL). It is also
showing on the bottom right the weight of the load, the maximum load
allowed and the height or the radius (select height or radius by pressing the
ENTER button).
}UP/DOWN buttons
Navigate through
windows
Load
SWL
Height/Radius
LED (lit) = TARE is activated.
2.4.2 Excavator window (2 of 3):
An illustration of an excavator showing the current load, the allowed load
and the safe working load (%SWL). It also shows the Radius from the base
of the boom to the lifting point and the Height from the ground to the lifting
point. The red and green arrows shows permitted and prohibited movements.
% SWL
Radius
Current load
Max load allowed
Height between
ground and lifting
point
}UP/DOWN buttons
Navigate through
windows

19
i4000 RCL For Excavator Instruction Manual
55M4000UBE00-A
Safe Working Load
Slew Angle
Load
Selected Duty
Height between
ground and lifting
point
Height between
ground and highest
boom position *
* The parameter indicating the boom tip height should only be used
as a guide and NOT as an indicator of whether the excavator clears a
narrow pass.
It allows the display of multiple sensors, providing a good overview of the
excavator during operation.
2.4 Lifting Tab (continued)
2.4.3 Indicator window (3 of 3):
2.5 Range limiting tab (optional)
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The range limiting tab is only available once activated in the calibration.
}UP/DOWN buttons
Navigate through
windows
Overall Height
Range limiting tab
Slewing
Detected
Radius

55M4000UBE00-A
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i4000 RCL For Excavator Instruction Manual
If one or more range limits have been programmed, such as Height limit,
6OHZOLPLW6OHZDQGYDULDEOHKHLJKWOLPLW+HLJKWZLWKIUHH]RQHRU6OHZDQG
YDULDEOHUDGLXVKHUHDUHWKHVLJQLÀFDWLRQVRIHDFKOLJKWVDQGDODUPV5HIHUWR
section 6 - RANGE LIMITING for more details).
When approaching a programmed range limit, the corresponding
arrow(s) blinks yellow, the warning light blinks YELLOW and the
audible alarm can be heard intermittently.
After reaching a programmed range limit, the corresponding arrow(s)
blinks red, the warning light turns RED and the audible alarm can be
heard continuously.
WARNING
LIGHT
BLINKING
YELLOW : APPROACHING
RED : REACHED
* A warning message will also be displayed on the other tabs to inform
the operator that a range limit has been reached.
B
B
Press DOWN button to mute alarm.
Limit in approach Limit reached
2.5 Range limiting tab (continued)
2.5.1 Meaning of each lights and messages of the range limiter